Integrated wafer pod-load/unload and mass-transfer system

ABSTRACT

A system includes an interface for receiving a pod having a carrier that receives wafers, and that is initially enclosed within a base and a pod cover. The system also includes a mechanism that transfers an exposed carrier between the interface and a platform of a mass-transfer machine included in the system. The machine includes a gantry arm for transferring the carrier between the platform and a transfer station. A retainer assembly is positionable over the carrier at the transfer station, and over a process carrier that is used in a processing tool. Moveable retainers of the assembly receive and hold wafers. The machine includes an elevator that moves between the transfer station and the process carrier. The elevator extends and retracts for transferring wafers between the retainers and either the carrier or the process carrier. A turntable, that receives the process carrier, permits automatically reorienting wafers.

CLAIM OF PROVISIONAL APPLICATION RIGHTS

This application claims the benefit of U.S. Provisional PatentApplication No. 60/039,332 on Mar. 17, 1997, and is a continuation ofapplication Ser. No. 09/038,809 filed Mar. 11, 1998, which issued Mar.9, 1999, as U.S. Pat. No. 5,885,045.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to silicon wafer handlingmachines, and more particularly to systems adapted for automaticallyunloading silicon wafers from a Standard Mechanical InterFace (“SMIF”)pod and then transferring such wafers to a process carrier, andconversely.

2. Description of the Prior Art

Certain semiconductor wafer processing operations require that a numberof disk-shaped silicon wafers be loaded into a process carrier arrangedin a vertical orientation. Examples of such processes are “wet bench”processing and horizontal diffusion furnace processing. Presently,silicon wafers are transported between processing tools in a SMIF podwhich orients the wafers horizontally. Accordingly, in addition totransferring wafers between the SMIF pod and the process carrier,performing any wafer processing operation in which the wafers must beoriented vertically requires reorienting the wafers from theirhorizontal orientation in the SMIF pod into a vertical orientation inthe process carrier. In addition to reorientation of wafers between theSMIF pod and the process carrier, frequently the process carrier iscapable of holding more wafers than the SMIF pod. Accordingly, ingeneral preparing wafers for a process in which they are verticallyoriented requires:

1. removing a SMIF pod's wafer carrier from within the protectiveenvironment provided by the SMIF pod;

2. removing the wafers from the SMIF pod's wafer carrier;

3. rotating the wafers from a horizontal to a vertical orientationeither while they are present in, or after they are removed from, theSMIF pod's wafer carrier;

4. depositing the now vertically oriented wafers into a process carrier;and

5. perhaps performing the preceding operations more than once to combinewafers from more than one SMIF pod's wafer carrier into one processcarrier.

To prevent contamination of silicon wafers during processing, presentsemiconductor processing technology requires that all of the precedingoperations be performed automatically by a machine without humanintervention in the process. Thus far, automation of this wafer handlingprocess has been achieved by cascading a general purpose SMIF pod-loadinterface apparatus with a wafer mass-transfer machine with a processtool, e.g. a wet bench or a horizontal diffusion furnace. Assembling anentire apparatus for either of these process tools therefore results intwo mechanical interfaces, i.e. the mechanical interface between theSMIF pod-load interface apparatus and the wafer mass-transfer machine,and the mechanical interface between the wafer mass-transfer machine andthe process tool. Alignment of a mechanical interface, e.g. themechanical interface between the SMIF pod-load interface apparatus andthe wafer mass-transfer machine, can be so difficult that after the twodevices have been disconnected, perhaps for repair or maintenance,several hours may be required to properly realign them.

In addition to the mechanical interfaces, there also exist electricalinterfaces between the SMIF pod-load interface apparatus and a wafermass-transfer machine, and the wafer mass-transfer machine with theprocess tool. In particular, the electrical interfaces between each ofthe devices must be arranged so the combined devices operate in acoordinated manner. Interfacing the SMIF pod-load interface apparatuswith the wafer mass-transfer machine has proven to be troublesome andparticularly annoying for process tool manufacturers desirous of sellingan integrated system which includes the SMIF pod-load interface, thewafer mass-transfer machine, and the process tool.

In addition to the difficulties associated with interfacing the SMIFpod-load interface apparatus with the wafer mass-transfer machine, thecombined devices occupy more floor space than desirable, and operatecomparatively slowly because they are general purpose rather thanspecial purpose devices. For example, a standard pod load interfaceopens a SMIF pod and transfers the wafer carrier to the process tool.For certain processes, the wafers must also be transferred from theoriginal carrier to a different carrier. Under such circumstances, awafer transfer machine has to be combined with a pod load interface totranslate a carrier from a position within the pod load interface to aposition within the wafer mass-transfer machine. For translating theSMIF pod's wafer carrier from one location to another location,generally the pod load interface includes an arm having at least tworotary joints which merely picks up the SMIF pod's wafer carrier,translates the carrier to a new location, and then set the SMIF pod'swafer carrier down. Accordingly, if the pod load interface is to alsoreorient the wafers from a horizontal orientation to a verticalorientation, an end-effector must be added to the standard pod loadinterface for performing the prescribed rotation.

In addition, the combined SMIF pod-load interface apparatus and wafermass-transfer machine unnecessarily replicate certain subsystems. Forexample, a general purpose SMIF pod-load interface and a wafermass-transfer machine each includes an environmental control system toprevent wafer contamination. Similarly, the SMIF pod load/unload deviceand wafer mass-transfer machine each include a separate electroniccircuit for controlling their respective operation.

In addition to a horizontal orientation for the silicon wafers withinthe SMIF pod, it is often desirable to arrange the wafers with thebackside of one wafer facing the frontside of the immediately adjacentwafer, or conversely. Generally, the backside of a silicon wafer is morelikely to be contaminated than the wafer's frontside. Therefore, duringwafer processing in which the wafers retain their SMIF pod's wafercarrier arrangement, contamination of the frontside of a wafer is morelikely than if the wafers were arranged backside-to-backside andfrontside-to-frontside. Such a rearrangement of the wafers into the moredesirable backside-to-backside and frontside-to-frontside orientation isdifficult to achieve with the combined SMIF pod-load interface apparatusand wafer mass-transfer machine.

SUMMARY OF THE INVENTION

An object of the present invention is to provide an integrated waferpod-load/unload and mass-transfer system having higher throughput.

Another object of the present invention is to provide an integratedwafer pod-load/unload and mass-transfer system that reduces mechanicalinterfaces.

Another object of the present invention is to provide an integratedwafer pod-load/unload and mass-transfer system that eliminateselectrical interface problems between the wafer transfer machine and thepod loader.

Another object of the present invention is to provide an integratedwafer pod-load/unload and mass-transfer system having lower cost.

Another object of the present invention is to provide an integratedwafer pod-load/unload and mass-transfer system that loads faster.

Another object of the present invention is to provide an integratedwafer pod-load/unload and mass-transfer system that occupies less floorspace.

Another object of the present invention is to provide an integratedwafer pod-load/unload and mass-transfer system that can provideback-to-back silicon wafer loading into a process carrier.

Briefly, the present invention integrates a SMIF pod loader, a wafertransfer machine, and mini-environment into a single system. Forexchanging wafers between a carrier contained in a SMIF pod and aprocess carrier, the integrated wafer pod-load/unload and mass-transfersystem links directly to a process tool. The pod load interfacemaintains an ultra clean environment for silicon wafers, and provides anergonomic load port platform height for operator manual pod loading. Acommon operator panel is used to control all aspects of the process tooloperation. The electronic controls are shared between several roboticelements.

The integrated pod-load/unload and mass-transfer system in accordancewith the present invention automatically transfers silicon wafersbetween a SMIF pod and a wafer processing tool. As is known to thoseskilled in the art, the SMIF pod includes a wafer carrier adapted toreceive a plurality of wafers. A base of the SMIF pod receives the wafercarrier and a SMIF pod cover mates with and seals to the base of theSMIF pod. In this way, the SMIF pod's cover and base completely enclosethe SMIF pod's wafer carrier and any wafers carried therein.

The pod-load/unload and mass-transfer system itself includes a podloader interface adapted to receive the SMIF pod, and either to exposeor to reenclose the SMIF pod's wafer carrier. The pod-load/unload andmass-transfer system also includes a carrier load mechanism that ismechanically coupled to the pod loader interface. The carrier loadmechanism transfers the SMIF pod's wafer carrier between a position inwhich the wafer carrier is exposed within the pod loader interface and aload platform.

Also included in pod-load/unload and mass-transfer system is amass-transfer machine that includes the load platform. The mass-transfermachine, which is mechanically coupled directly to the pod loaderinterface, includes a gantry arm for transferring the wafer carrierbetween the load platform and a first wafer transfer station included inthe mass-transfer machine. A retainer assembly, also included in themass-transfer machine is positionable over either the SMIF pod's wafercarrier, when the wafer carrier is present at the wafer transferstation, and over a process carrier used in the wafer processing tool.The retainer assembly includes moveable retainers adapted for receivingand holding wafers. The mass-transfer machine includes at least oneelevator moveable between positions in which the elevator is locatedeither beneath the wafer transfer station or beneath the processcarrier. The elevator extends and retracts for transfer-ring siliconwafers either between the wafer carrier present at the wafer transferstation and a position within the retainer assembly in which theretainers thereof may receive the wafers, or between the process carrierand a position within the retainer assembly in which the retainersthereof may receive the wafers. one embodiment of the present inventionincludes motorized turntable that receives the process carrier. Themotorized turntable used in combination with the wafer elevators and theretainer assembly permits automatically reorienting the silicon wafersfrom a frontside-to-backside orientation to a backside-to-backside andfrontside-to-frontside orientation.

These and other features, objects and advantages will be understood orapparent to those of ordinary skill in the art from the followingdetailed description of the preferred embodiment as illustrated in thevarious drawing figures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side elevational view of an integrated wafer pod-load/unloadand mass-transfer system in accordance with the present inventiondepicting a pod load interface on which rests a SMIF pod, a SMIF pod'swafer carrier unloaded from the SMIF pod and resting on a load platformof a wafer transfer machine, and a mounting plate to which both thewafer pod-load/unload device and the mass-transfer machine are secured;

FIG. 2 is a front elevational view of the integrated waferpod-load/unload and mass-transfer system taken along the line 2—2 inFIG. 1;

FIG. 3 is a plan view of the integrated wafer pod-load/unload andmass-transfer system taken along the line 3—3 in FIGS. 1 and 2;

FIG. 4 is the side elevational view of the integrated waferpod-load/unload and mass-transfer system of FIG. 1 depicting amini-environment for enclosing a SMIF pod's wafer carrier, two carriersloaded onto the wafer transfer machine, and is partially cut-away alonga line 4—4 in FIG. 3 to illustrate operation of a carrier loadmechanism;

FIGS. 5a-5 e are schematic diagrams forming a sequence that illustratestransfer of a SMIF pod's wafer carrier from one location to anotherwithin the wafer transfer machine by a gantry included in the integratedwafer pod-load/unload and mass-transfer system;

FIGS. 6a through 6 c respectively are side elevational, frontelevational, and plan views of an alternative embodiment integratedwafer pod-load/unload and mass-transfer system with the frontelevational view 6 b being taken along the line 6 b—6 bin FIGS. 6a and 6c;

FIG. 7 is a plan view of the mounting plate depicted in FIG. 1;

FIG. 8 is a partially cross-sectioned front elevational view of themounting plate taken along the line 8—8 in FIG. 7; and

FIG. 9 is a perspective view showing the retainer assembly and retainerarm which takes wafers in a horizontal array from two wafer carriers(each holding up to twenty-five wafers) at one loading platform andtransfers the wafers to a larger carrier (holding up to fifty wafers) atanother platform arranging the wafers in a backside-to-backside andfrontside-to-frontside orientation.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIGS. 1-4 depict different views of an integrated wafer pod-load/unloadand mass-transfer system in accordance with the present inventionreferred to by the general reference character 20. The system 20includes a SMIF pod-load interface 22, a wafer mass-transfer machine 24,a mini-environment 26 and an L-shaped mounting plate 28. As illustratedwith dashed lines in FIGS. 2 and 3, the system 20 abuts a process tool32 which may be a “wet bench” for liquid immersion processing of siliconwafers, a horizontal diffusion furnace, or any other processing toolwhich requires vertically oriented wafers. The process tool 32 includesa robot arm (not depicted in any of the FIGS.) that positions a processcarrier (also not depicted in FIGS. 1-4) onto the wafer mass-transfermachine 24 either to receive wafers from, or deliver wafers to, thesystem 20.

As illustrated in FIGS. 1 and 4, the SMIF pod-load interface 22 receivesa SMIF pod 36 onto a loading platform 38. The pod load interfaceincludes a pod present sensor (not separately depicted in any of theFIGS.) for detecting arrival or removal of a pod. The SMIF pod-loadinterface 22 includes a motorized pod opener mechanism (not separatelydepicted in any of the FIGS.). To open the SMIF pod 36, the pod openermechanism releases a SMIF cover 44 from a SMIF base 46, and then raisesthe SMIF cover 44 above a SMIF pod's wafer carrier 48 carried within theSMIF pod 36 while concurrently enclosing the SMIF pod's wafer carrier 48within the mini-environment 26. An optical sensor (not separatelydepicted in any of the FIGS. and distinct from the pod present sensordescribed above) detects the presence of the SMIF pod's wafer carrier 48in the SMIF pod 36. When the SMIF cover 44 is raised, the SMIF pod'swafer carrier 48 remains within the mini-environment 26 to be therebymaintained in a class 1 environment. The SMIF pod's wafer carrier 48 ineach SMIF pod 36 holds twenty-five (25) silicon wafers that are orientedhorizontally. The SMIF pod-load interface 22 is similar to thatdescribed in U.S. patent application Ser. No. 08/400,039 filed Mar. 7,1995, in the name of John Rush, that is entitled “Pod Loader Interface,”and that is hereby incorporated by reference.

A window 52, that pierces a pod-loader-interface bulkhead 54, permits amotorized carrier load mechanism 56 to access the SMIF pod's wafercarrier 48. The carrier load mechanism 56 which is supported from thebulkhead 54, and includes an end-effector 58 that rotates about ahorizontal axis 62 to thereby enter through the window 52 into themini-environment 26. After entering the mini-environment 26, theend-effector 58 engages the SMIF pod's wafer carrier 48. Theend-effector 58 then raises the SMIF pod's wafer carrier 48 off guides(not separately depicted in any of the FIGS.), and carrying the SMIFpod's wafer carrier 48 rotates in the reverse direction about thehorizontal axis 62 thereby withdrawing out of the window 52 so wafers 64in the SMIF pod's wafer carrier 48 become oriented vertically over thewafer mass-transfer machine 24. The end-effector 58 then deposits theSMIF pod's wafer carrier 48, about the center of gravity of the SMIFpod's wafer carrier 48, onto a load platform 72 of the wafermass-transfer machine 24. Dedicating the carrier load mechanism 56 totransferring the SMIF pod's wafer carrier 48 between the SMIF pod-loadinterface 22 and the wafer mass-transfer machine 24 results in a simplemechanism that operates much more swiftly than previous systems.

Directly coupling the SMIF pod-load interface 22 to the wafermass-transfer machine 24 reduces errors caused by mechanical interfacesbetween two independent units. The SMIF pod-load interface 22 and thewafer mass-transfer machine 24 also share common control electronicsthereby eliminating potential software communications problems.

The wafer mass-transfer machine 24 transfers wafers 64 from SMIF pods'wafer carriers 48 to a process carrier used in the process tool 32. Thewafer mass-transfer machine 24 includes a motorized gantry arm 76 that,as illustrated in FIGS. 5a-5 e, rises to pick-up the SMIF pod's wafercarrier 48 resting on the load platform 72, and transports the SMIFpod's wafer carrier 48 horizontally away from the SMIF pod-loadinterface 22 to transfer stations 78 of the wafer mass-transfer machine24. The system 20 can be configured so the gantry arm 76 transports theSMIF pod's wafer carrier 48 different distances within the wafermass-transfer machine 24 as required for compatibility with processcarrier of the process tool 32.

The SMIF pod-load interface 22 and the gantry arm 76 illustrated inFIGS. 1-4 may load one or preferably two SMIF pods' wafer carriers 48onto the wafer mass-transfer machine 24 at transfer stations 78 asillustrated in FIG. 4. After the SMIF pods' wafer carriers 48 arelocated in the transfer stations 78, a motorized retainer assembly 82,that is elevated above the SMIF pods' wafer carriers 48, moveshorizontally across a fixed top plate 84 of the wafer mass-transfermachine 24 to a position over the SMIF pods' wafer carriers 48. Dualpedestal, U-shaped, motorized wafer elevators 86 then rise through thetop plate 84 to lift the wafers 64 out of the SMIF pods' wafer carriers48 up to the retainer assembly 82. If necessary, after the waferelevators 86 raises the wafers 64 above the SMIF pods' wafer carriers 48but before elevating them to the retainer assembly 82, a motorizedindexing mechanism 88 moves the wafer elevator 86 furthest from the SMIFpod-load interface 22 horizontally toward or away from the SMIF pod-loadinterface 22. Moving the wafer elevator 86 horizontally adjusts theposition of the wafers 64 lifted out of the SMIF pod's wafer carrier 48furthest from the wafer mass-transfer machine 24 to match therequirements of the process carrier of the process tool 32. A pair ofelongated motorized retainers 92 carried within and extending almost theentire length of the retainer assembly 82 then rotate under the wafers64, then supported on the wafer elevators 86, to receive the wafers 64.The wafer elevators 86 then retract downward beneath the top plate 84,and the retainer assembly 82 now carrying the wafers 64 moveshorizontally across the top plate 84 to position the wafers 64 over theprocess carrier of the process tool 32. The wafer elevators 86 againrise to pick-up the wafers 64, the retainers 92 then retract, and thewafer elevators 86 then descend to deposit the wafers 64 into theprocess carrier. The robot arm included in the process tool 32 thentransfers the process carrier carrying the wafers 64 into the processtool 32 for processing. Operating in the manner described thus far, thesystem 20 may load up to fifty (50) wafers 64 at a time from two (2)SMIF pods' wafer carriers 48 into a single process carrier.

After the wafers 64 undergo processing in the process tool 32, a reversesequence of operations removes the wafers 64 from the process carriersand stores them back into the SMIF pod 36.

FIG. 7 illustrates the L-shaped mounting plate 28 upon which rest bothan intermediate plate 94 for the SMIF pod-load interface 22, and a baseplate 96 for the wafer mass-transfer machine 24. To facilitate radialalignment of the base plate 96 to the process tool 32, the base plate 96is secured to the L-shaped mounting plate 28 by threaded bolts 98 whichpass through large apertures piercing the base plate 96 to screw intomating threaded holes in the L-shaped mounting plate 28. A large washer102 is interposed between the head of each bolt 98 and the base plate96. In a similar manner, the intermediate plate 94 is also secured tothe L-shaped mounting plate 28 using bolts 98 passing through largeapertures piercing the intermediate plate 94 and by large washers 102that encircle the bolts 98. Both the intermediate plate 94 and a baseplate 95 of the SMIF pod-load interface 22 are joined together by guidepins 104 that fit into apertures piercing the intermediate plate 94 andthe base plate 95. The guide pins 104 ensure accurate repositioning ofthe SMIF pod-load interface 22 on the L-shaped mounting plate 28 afterremoval therefrom for repair or maintenance.

Referring now to FIG. 8, the L-shaped mounting plate 28 rests upon apair of guide rails 103 that extend along sides of the L-shaped mountingplate 28. A pair of stiffeners 105, secured to the L-shaped mountingplate 28 beneath the L-shaped mounting plate 28, extend from below thewafer mass-transfer machine 24 to below the SMIF pod-load interface 22to support and stiffen that portion of the L-shaped mounting plate 28which projects outward beyond the guide rails 103. Supporting theL-shaped mounting plate 28 on the guide rails 103 permits sliding theentire system 20 forward or backward horizontally with respect to theprocess tool 32 to facilitate maintenance or repair. Bolts 108 lock thesystem 20 to the guide rails 103 during normal operation. The guiderails 103 rest upon and are secured to an interface plate 112. Theinterface plate 112 in turn is supported from a frame 114 of the processtool 32 by four threaded jack screws 116, only two of which appear inFIG. 8. Four threaded bolts 118, only two of which appear in FIG. 8,pass through apertures piercing the interface plate 112 to secure theinterface plate 112 to the frame 114. Adjustment of the jack screws 116permits lowering the interface plate 112 toward or raising the interfaceplate 112 away from the frame 114. In this way, the system 20 may beraised, lowered and tilted with respect to the process tool 32 bothparallel to the process tool 32 and orthogonal to the process tool 32.The adjustments permitted by this structure facilitate aligning themechanical interface between the system 20 and the process tool 32 bothradially and rectilinearly.

FIGS. 6a-6 c depict an alternative embodiment of the system 20 thatincludes two (2) SMIF pod-load interfaces 22. Those elements depicted inFIGS. 6a-6 c that are common to the system 20 depicted in FIGS. 1-5carry the same reference numeral distinguished by a prime (“′”)designation. The two (2) SMIF pod-load interfaces 22′ and carrier loadmechanisms 56′ of the alternative embodiment system 20′ respectivelytransfer SMIF pods' wafer carriers 48′ onto two (2) load platforms 72′of the wafer mass-transfer machine 24′. Similar to the system 20, asingle gantry arm 76′ of the wafer mass-transfer machine 24′appropriately position the SMIF pods' wafer carriers 48′ horizontallywith respect to the SMIF pod-load interfaces 22′ over the wafer elevator86′. However, the system 20′ locates the wafers 64′ in the SMIF pods'wafer carriers 48′ from one of the SMIF pod-load interface 22′ half-waybetween the wafers 64′ in the SMIF pods' wafer carriers 48′ from theother SMIF pod-load interface 22′.

With the wafers 64′ from the two SMIF pod-load interfaces 22′ locatedhalf-way between each other, similar to the system 20, the waferelevator 86′ then lifts the wafers 64′ out of the SMIF pods' wafercarriers 48′ up to the retainer assembly 82′. However, instead of asingle pair of retainers 92 as in the system 20, the retainer assembly82′ of the system 20′ includes two (2) pairs of intermeshing retainers92′ that are adapted to hold the wafers 64′ from both of the SMIFpod-load interfaces 22′ at a pitch, i.e. spacing between immediatelyadjacent wafers 64′, that is one-half of the pitch between immediatelyadjacent wafers 64′ in the SMIF pods' wafer carriers 48′. In this way,the system 20′ combines on the retainer assembly 82′ the twenty-five(25) wafers 64′ from four (4) SMIF pods' wafer carriers 48′ into asingle group of one hundred (100) wafers 64′ for loading into a processcarrier 122.

As illustrated in FIG. 9, the mass-transfer machine 24′ may also includea motorized turntable 128 at one of three (3) transfer stations 78′ forreversing the direction of a larger wafer carrier 132 resting thereupon.As described in greater detail below, inclusion of the motorizedturntable 128 in the mass-transfer machine 24′ permits automaticreorientation of wafers from two (2) SMIF pods' wafer carriers 48 into abackside-to-backside and frontside-to-frontside orientation within thesingle wafer carrier 132. To effect such a reorientation of the wafers,first two SMIF pods' wafer carriers 48′ are deposited respectively ontotwo (2) of the transfer stations 78 from a SMIF pod-load interface, notdepicted in FIG. 9. After the SMIF pods' wafer carriers 48′ are presenton the transfer stations 78′, the motorized retainer assembly 82′, moveshorizontally to a position above the SMIF pods' wafer carriers 48′.Analogously to the description set forth above in connection with FIGS.1-4, notorized wafer elevators then rise to lift the wafers out of theSMIF pods' wafer carriers 48′ up to the retainer assembly 82′. Two pairsof elongated motorized retainers 92′, carried within and occupyingalmost the entire length of the retainer assembly 82′, then rotate underthe wafers to receive the wafers. As described above, while the wafers64 are being raised toward the retainer assembly 82′ the wafer elevatorsmove closer together to match the pitch of all the wafers carried by theretainer assembly 82′ with the pitch of the wafer carrier 132. The waferelevators then retract downward beneath the transfer stations 78′, andboth the elevators and the retainer assembly 82′ now carrying as many asfifty (50) wafers move horizontally across the mass-transfer machine 24′to align with the wafer carrier 132.

With the wafers now disposed in the retainer assembly 82′ over themotorized turntable 128, a wafer elevator included therein rises toreceive from alternating locations along the retainers 92′ as many astwenty-five (25) of the wafers, i.e. twelve (12) from one of the SMIFpod's wafer carrier 48′ and thirteen (13) from the other SMIF pod'swafer carrier 48′ or the converse. The elevator, carrying up totwenty-five (25) wafers, then descends into the mass-transfer machine 24thereby depositing the wafers into the wafer carrier 132. After thewafers are deposited in the wafer carrier 132, the motorized turntable128 rotates 180° so the frontsides of the wafers in the wafer carrier132 face the backsides of the wafers still remaining above in theretainer assembly 82′. The wafer elevator carrying the now reorientedwafers again rises to the retainer assembly 82′ to receive the wafersremaining there. Carrying all the wafers now arranged in abackside-to-backside and frontside-to-frontside orientation, theelevator again descends into the mass-transfer machine 24′ to depositthe reoriented wafers into the wafer carrier 132. A robot arm includedin a process tool then transfers the wafer carrier 132 and thereoriented wafers into the tool for processing. As described above,organizing wafers backside-to-backside and frontside-to-frontside withinthe wafer carrier 132 for processing within the process tool eliminatestransfer of contamination from the backside of one wafer to thefrontside of the immediately adjacent wafer.

After the wafers have been processed in the tool, reversing the sequenceof operations describe above transfers the wafers from the wafer carrier132 back into the SMIF pods' wafer carriers 48′ restoring all of thewafers to a uniform orientation.

Although the present invention has been described in terms of thepresently preferred embodiment, it is to be understood that suchdisclosure is purely illustrative and is not to be interpreted aslimiting. Consequently, without departing from the spirit and scope ofthe invention, various alterations, modifications, and/or alternativeapplications of the invention will, no doubt, be suggested to thoseskilled in the art after having read the preceding disclosure.

What is claimed is:
 1. An integrated pod-load/unload and mass-transfersystem for automatically transferring wafers between a StandardMechanical InterFace (“SMIF”) pod and a carrier used in waferprocessing; the SMIF pod including: a wafer carrier adapted to receive aplurality of wafers; a base which receives the wafer carrier; and a podcover which mates with and seals to the base of the SMIF pod therebyenclosing the wafer carrier and any wafers received therein within thepod cover and the base; the pod-load/unload and mass-transfer systemcomprising: pod loader interface adapted for receiving the SMIF pod, forexposing a wafer carrier initially enclosed within the SMIF pod, and forreenclosing the wafer carrier within the SMIF pod, said pod loaderinterface including a bulkhead that is pierced by a window; a carrierload mechanism that is mechanically coupled to said pod loader interfaceand is supported from the bulkhead, a portion of said carrier loadmechanism entering into and withdrawing out of the window of thebulkhead while said carrier load mechanism transfers the wafer carrierbetween a position in which the wafer carrier is exposed within said podloader interface and a wafer transfer station; and a mass-transfermachine that includes the wafer transfer station and which ismechanically coupled directly to said pod loader interface, saidmass-transfer machine including: a retainer assembly positioned over thewafer carrier when the wafer carrier is present at the wafer transferstation, said retainer assembly including moveable retainers adapted forreceiving wafers; and an elevator that is both: extensible fortransferring wafers between a wafer carrier present at the wafertransfer station and a position within said retainer assembly in whichthe retainers thereof may receive the wafers; and retractable fortransferring wafers between the retainers of the retainer assembly whichhave received wafers and a wafer carrier present at the wafer transferstation.
 2. The pod-load/unload and mass-transfer system of claim 1wherein said carrier load mechanism reorients the wafer carrier whiletransferring the wafer carrier between the pod loader interface and thewafer transfer station.
 3. The pod-load/unload and mass-transfer systemof claim 2 wherein said carrier load mechanism for transferring andreorienting the wafer carrier, includes an end-effector that: rotates ina first direction about a horizontal axis to engage the wafer carrierthen disposed in said pod loader interface with wafers received in thewafer carrier being oriented horizontally; raises the wafer carrier;carrying the wafer carrier, rotates about the horizontal axis in asecond direction that is reversed from the first direction so thatwafers present in said wafer carrier become oriented vertically over themass-transfer machine, and lowers to deposit the wafer carrier onto saidmass-transfer machine.
 4. The pod-load/unload and mass-transfer systemof claim 1 wherein said elevator is U-shaped.
 5. The pod-load/unload andmass-transfer system of claim 1 wherein the mass-transfer machine isdirectly coupled to said pod loader interface by a rigid plate thatreceives both the mass-transfer machine and the pod loader interface. 6.The pod-load/unload and mass-transfer system of claim 5 wherein theplate includes an indexing means for ensuring precise mechanicalpositioning and repositioning of the pod loader interface with respectto said mass-transfer machine so that the pod loader interface may beremoved and replaced precisely in a fast and easy manner.
 7. Thepod-load/unload and mass-transfer system of claim 6 wherein the indexingmeans includes holes that pierce both the plate and a base plate of saidpod loader interface, together with pins that are received into theholes, each pin extending between the plate and the base plate of saidpod loader interface.
 8. The pod-load/unload and mass-transfer system ofclaim 5 wherein the plate is received by guide rails that are coupled tothe wafer transfer station, the guide rails permitting thepod-load/unload and mass-transfer system to slide horizontally withrespect to the wafer transfer station to facilitate maintenance orrepair thereof.
 9. The pod-load/unload and mass-transfer system of claim8 further comprising adjusting means disposed between the plate and thewafer transfer station for raising, lowering and tilting thepod-load/unload and mass-transfer system with respect to the wafertransfer station.
 10. The pod-load/unload and mass-transfer system ofclaim 4 wherein the adjusting means includes jack screws that arecoupled to the plate.
 11. The pod-load/unload and mass-transfer systemof claim 5 further comprising adjusting means disposed between the plateand the wafer transfer station for raising, lowering and tilting thepod-load/unload and mass-transfer system with respect to the wafertransfer station.
 12. The pod-load/unload and mass-transfer system ofclaim 11 wherein the adjusting means includes jack screws that arecoupled to the plate.
 13. An integrated pod-load/unload andmass-transfer system for automatically transferring wafers between a podand a carrier used in wafer processing; the pod including: a wafercarrier adapted to receive a plurality of wafers; a base which receivesthe wafer carrier; and a pod cover which mates with and seals to thebase of the pod thereby enclosing the wafer carrier and any wafersreceived therein within the pod cover and the base; the pod-load/unloadand mass-transfer system comprising: pod loader interface adapted forreceiving the pod, for exposing a wafer carrier initially enclosedwithin the pod, and for reenclosing the wafer carrier within the pod,said pod loader interface including a bulkhead that is pierced by awindow; a carrier load mechanism that is mechanically coupled to saidpod loader interface and is supported from the bulkhead, a portion ofsaid carrier load mechanism entering into and withdrawing out of thewindow of the bulkhead while said carrier load mechanism transfers thewafer carrier between a position in which the wafer carrier is exposedwithin said pod loader interface and a wafer transfer station; and amass-transfer machine that includes the wafer transfer station and whichis mechanically coupled directly to said pod loader interface, saidmass-transfer machine including: a retainer assembly positioned over thewafer carrier when the wafer carrier is present at the wafer transferstation, said retainer assembly including moveable retainers adapted forreceiving wafers; and an elevator that is both: extensible fortransferring wafers between a wafer carrier present at the wafertransfer station and a position within said retainer assembly in whichthe retainers thereof may receive the wafers; and retractable fortransferring wafers between the retainers of the retainer assembly whichhave received wafers and a wafer carrier present at the wafer transferstation.
 14. The pod-load/unload and mass-transfer system of claim 13wherein said carrier load mechanism reorients the wafer carrier whiletransferring the wafer carrier between the pod loader interface and thewafer transfer station.
 15. The pod-load/unload and mass-transfer systemof claim 14 wherein said carrier load mechanism for transferring andreorienting the wafer carrier, includes an end-effector that: rotates ina first direction about a horizontal axis to engage the wafer carrierthen disposed in said pod loader interface with wafers received in thewafer carrier being oriented horizontally; raises the wafer carrier;carrying the wafer carrier, rotates about the horizontal axis in asecond direction that is reversed from the first direction so thatwafers present in said wafer carrier become oriented vertically over themass-transfer machine, and lowers to deposit the wafer carrier onto saidmass-transfer machine.
 16. The pod-load/unload and mass-transfer systemof claim 13 wherein said elevator is U-shaped.
 17. The pod-load/unloadand mass-transfer system of claim 13 wherein the mass-transfer machineis directly coupled to said pod loader interface by a rigid plate thatreceives both the mass-transfer machine and the pod loader interface.18. The pod-load/unload and mass-transfer system of claim 17 wherein theplate includes an indexing means for ensuring precise mechanicalpositioning and repositioning of the pod loader interface with respectto said mass-transfer machine so that the pod loader interface may beremoved and replaced precisely in a fast and easy manner.
 19. Thepod-load/unload and mass-transfer system of claim 18 wherein theindexing means includes holes that pierce both the plate and a baseplate of said pod loader interface, together with pins that are receivedinto the holes, each pin extending between the plate and the base plateof said pod loader interface.
 20. The pod-load/unload and mass-transfersystem of claim 17 wherein the plate is received by guide rails that arecoupled to the wafer transfer station, the guide rails permitting thepod-load/unload and mass-transfer system to slide horizontally withrespect to the wafer transfer station to facilitate maintenance orrepair thereof.
 21. The pod-load/unload and mass-transfer system ofclaim 20 further comprising adjusting means disposed between the plateand the wafer transfer station for raising, lowering and tilting thepod-load/unload and mass-transfer system with respect to the wafertransfer station.
 22. The pod-load/unload and mass-transfer system ofclaim 21 wherein the adjusting means includes jack screws that arecoupled to the plate.
 23. The pod-load/unload and mass-transfer systemof claim 11 further comprising adjusting means disposed between theplate and the wafer transfer station for raising, lowering and tiltingthe pod-load/unload and mass-transfer system with respect to the wafertransfer station.
 24. The pod-load/unload and mass-transfer system ofclaim 23 wherein the adjusting means includes jack screws that arecoupled to the plate.